Indexed pallet

ABSTRACT

A pallet ( 10 ) includes a rectangular support deck ( 12 ) having a substantially planar upper supporting surface including a plurality of channels ( 16 ) formed therein extending across the pallet ( 10 ). The deck ( 12 ) includes support members ( 14 ) extending from an underside of the deck ( 12 ) that nest in recesses formed in the upper surface of the deck. An alignment portion ( 40 ) is formed at a center point along the first edge of the deck and a second alignment portion is formed at a center oint of an opposed edge of the deck. An alignment portion ( 40 ) includes angled sides for receiving a tapered member of a complementary device ( 100 ).

This application is a 371 of PCT/US 00/04279 filed Feb. 18, 2000 whichis a continuation of U.S. Ser. No. 09/253624 filed Feb. 19, 1999, U.S.Pat. No. 6,209,464.

BACKGROUND

1. Field of the Invention

The present invention relates to a pallet and in particular, to anindexed pallet and alignment system for aiding in positioning the palletfor loading and unloading.

2. Prior Art

Pallets for supporting various types of articles are well known. Palletsare made of many materials including wood, metal, fiberglass or moldedplastic, depending on the intended use and environments in which thepallets are used. Pallets generally provide a support for many differenttypes of articles and are adapted for use with many types of loadingequipment, including attachment to cranes or lifting from below byforklifts or manual pallet jacks.

Pallets are often constructed with a planar supporting upper surface andfeet, runners or other supports extending downward from below the planarsupport portion. In this manner, articles are raised off of the groundto prevent moisture, dirt and other debris from coming into contact withthe supported articles. When not in use, the pallets are typicallystored in a stacked configuration. The stacks may become very high andthe amount of space required for storing the pallets may be quiteexpansive.

Pallets often require precise positioning of the articles for loadingand unloading. Often channels are formed across the supporting surfaceso that tines or extended fingers may fit under the supported articlesinto the channels for aiding with alignment. However, this method mayintroduce imprecision due to variances and tolerances in the channelsinto which the tines or fingers extend in aligning and positioning ofthe articles for loading and unloading. This problem can be compoundedif measurements are taken from different positions, such as oppositeends of the pallet.

It can be seen then that a pallet is needed that is capable ofsupporting heavy loads and provides maximum support area that does notdamage articles being supported and are stackable when not in use. Inaddition, such pallets should provide for alignment of the pallets forloading and unloading in a precise manner without detracting from theutility of the pallet. Such an alignment system should preventmisalignment due to differences in tolerances from one end to the otherof the pallet.

SUMMARY

The present invention is directed to a stackable pallet and inparticular, to a pallet that includes an alignment portion to aid inprecisely positioning the pallet.

The pallet may be made of a molded plastic or other similar materialthat is light weight and provides sufficient strength to accommodate theanticipated loads. The pallet includes a deck with a substantiallyplanar upper surface and support portion extending downward from anunderside of the deck. The upper surface may include channels formedtherein and extending across the width of the deck. Ribs extending onthe underside of the deck preferably run crosswise to the channels sothat the deck has improved strength and rigidity. The underside of thedeck may also include indentations for receiving the support portions ofadjacent pallets stacked in a flip-flop configuration so that thesupports of one pallet inserted into the indentations of an adjacentinverted nested pallet. In this manner, the pallets may be stacked andnested, alternately inverted pattern requiring less overall height andless space for the stored pallets. The bottom of the support portionsare configured to also extend into recesses formed in the upper surfaceof the deck so that the decks nest slightly in a normal stackedconfiguration. This retards lateral sliding of the decks and providesalignment so that the stack is less likely to tip.

In addition, the pallets of the present invention include an alignmentnotch formed along the center line of one of the lengthwise edges of thepallet. The alignment notch has angling sides which align with andreceive a complementary alignment member from a device from thestructure with which the pallet is being aligned. The angling sidesprovide for a degree of self correcting alignment. With the notch alongthe center line, the tolerances and variations are decreased as aligningis always taken from the center point rather than one of the ends wherevariances and tolerances may compound.

These features of novelty and various other advantages whichcharacterize the invention are pointed out with particularity in theclaims annexed hereto and forming a part hereof. However, for a betterunderstanding of the invention, its advantages, and the objects obtainedby its use, reference should be made to the drawings which form afurther part hereof, and to the accompanying descriptive matter, inwhich there is illustrated and described a preferred embodiment of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like reference numerals andletters indicate corresponding structure throughout the several views:

FIG. 1 shows a perspective view of a first embodiment of a palletaccording to the principles of the present invention;

FIG. 2 is a top plan view of the pallet shown in FIG. 1;

FIG. 3 is a side elevational view of the pallet shown in FIG. 1;

FIG. 4 is an end elevational view of the pallet shown in FIG. 1;

FIG. 5 is a bottom plan view of the pallet shown in FIG. 1;

FIG. 6 is a side elevational view of pallets shown in FIG. 1 in astacked, nested configuration;

FIG. 7 is a side elevational view of pallets shown in FIG. 1 in analternately inverted stacking pattern;

FIG. 8 is a perspective view of the pallet shown in FIG. 1 with anindexing element of an alignment device;

FIG. 9 shows a top plan view of the pallet shown in FIG. 1 with thestackable pallet and indexing element engaged;

FIG. 10 shows an end detail view of the ends of the channels of thestackable pallet shown in FIG. 1;

FIG. 11 shows a side elevational view of a second embodiment of a palletaccording to the principles of the present invention;

FIG. 12 shows a top plan view of the embodiment shown in FIG. 11;

FIG. 13 shows a bottom plan view of the embodiment shown in FIG. 11;

FIG. 14 shows a bottom detail view of an alignment portion for thepallet shown in FIG. 11; and

FIG. 15 shows a sectional view taken along line 15—15 of FIG. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, there is shown a pallet, generally designated10. The pallet includes a deck portion 12 having a substantially planarupper surface and may include ribs 15 and channels 16 extending acrossthe upper surface. The channels 16 may receive supports or liftingdevices for the load. The ends of the ribs 15 are tapered to aidinsertion. The pallet 10 includes support members 14 extending downwardfrom an underside of the deck 12. The support portions 14 are spacedapart from one another to provide a wide stable base for the pallet andadapted to receive forklift tines and manual pallet jacks. The supports14 at the corner include vertical sides that are substantially flushwith the edges of the deck 12, as shown in FIGS. 3 and 4.

As also shown in FIG. 2, the upper surface of the deck 12 includesrecesses 18 formed for nesting of the pallets 10 when stacked. Therecesses 18 define center portions 20 extending to the upper surface ofthe deck 12 that are configured for nesting and aligning with bottomdepressions 24 and lower surfaces formed in the bottom of the supportportions 14, shown in FIG. 5. The lower surfaces 22 of the supportportions 14 have a profile complementary to the recesses 18 so that thepallets 10 nest when stacked to prevent lateral movement between stackedpallets 10. Referring again to FIG. 5, the underside of the pallet 10includes bottom support ribs 26 extending across the length of thepallet. The ribs 26 extend perpendicular to the ribs 15 and channels 16on the top of the deck 12 for improved support and rigidity. The nestingrecesses 18 also provide compatibility with the channels 16 andpreferably extend to a depth no greater than the channels 16.

The underside of the deck 12 includes cavities 28 formed therein thatare spaced and configured for receiving lower surfaces 22 of the supportportions 14. In this manner, pairs of the pallets 10 may be stacked in aflip-flop configuration with greater nesting occurring. The pairs ofpallets 10 are stacked slightly offset to one another so that thesupport portions 14 of one pallet 10 align with and extend into thebottom cavities 28 of an inverted adjacent pallet 10. This configurationprevents lateral sliding between pairs of complementary pallets 10,requiring less space for pallet storage and shipping.

Referring again to FIG. 1, the pallet 10 includes an alignment section40 shown as a notch along opposed edges of the planar deck 12. Thenotches 40 are substantially “V” shaped and may include an enlarged tipportion 42. The alignment section is preferably positioned along thecenter line of the long edge of the deck 12. In this manner, moreprecise alignment is achieved as differences due to tolerances aremeasured from the center line rather than accumulating over the entirelength of the pallet 10. Mistakes due to alignment from different onesof the two ends are also eliminated. The planar deck 12 has an alignmentsection 40 along both of the longer edges of the deck 12 in a preferredembodiment so that either of the opposed edges may be used foralignment. The alignment section 40 is configured for mating with analignment member 102 of a stationary device 100 with which the pallet 10is being aligned, as shown in FIGS. 6 and 7. The alignment member 102has a substantially triangular end portion having angling surfaces 104.The pallet 10 is aligned by moving the deck so that the alignmentsection 40 engages the alignment member 102. As the angled sides of thenotch portion 40 and the angling surfaces 104 engage one another, theyprovide for self-alignment as the pallet 10 is moved closer to thestationary device 100, as shown in FIG. 7. The system providesself-alignment and assures repeated identical positioning among allpallets 10 as they are aligned with the device 100. This allows preciseplacement of the load for handling equipment.

Referring now to FIG. 10, the channels 16 further from the alignmentsection 40 are wider than the channels closer to the alignment section.Channels 16A have a first width, channels 16B have a second widthgreater than the first width, and channels 16C have a third widthgreater the first or second width. In some instances, elongated tines,commonly known as swords, are in a fixed position when inserted into thechannels 16 of the pallet 10. Gradually widening channels 16A, 16B and16C allow for variations due to compounded tolerances in the channelsfurthest from the center of the pallet 10. The swords may be easilyinserted as width of the channels 16 increases in a manner somewhatcorresponding to increased variations from compounded tolerances.Moreover, since the alignment is based from the center of the pallet 10,the variations can only compound over half the length of the pallet 10,thereby decreasing the maximum variations as compared to alignment fromone or the other of the ends. In a preferred embodiment, the centerlinesof the channels 16A, 16B and 16C remain evenly spaced apart even thoughthe channel width increases, as the swords are evenly spaced apart.

The alignment system provides a self-centering mechanism and providesfor precise alignment while minimizing differences in tolerances oralignment from different ends of the pallet 10. The pallet 10 may be alight weight molded monolithic element that includes alignment features40.

Referring now to FIG. 11, there is shown a second embodiment of apallet, generally designated 210. The pallet 210 is similar to thepallet 10 shown in FIG. 1, however, the second embodiment pallet 210includes a different notch 240 formed for alignment of the pallet.Opposed notch portions 240 are formed below the planar deck 212proximate a centerline of the pallet 210, as explained hereinafter, anddo not extend up to the deck 212. With this configuration, the planardeck 212 does not include a notched portion and is extended to the edgeof the pallet, so that a continuous straight edge is formed. Without acenter notch formed in each side, increased support area is provided.The pallet 210 includes a number of supporting members 214 extendingdownward from the underside of the deck 212. Ribs 215 extend across theupper surface of the planar deck 212, as shown in FIG. 13. Channels 216are formed between the ribs 215 across the upper surface of the planardeck 212, as shown in FIG. 12, and may be spaced similarly to channels16. The planar deck 212 also includes banding holes 218 extendingthrough the planar deck 212 in the channels 216 and configured toreceive straps for securing loads on the pallets 210. The banding holes218 may also be combined with the recesses 18 for improved stacking andloading.

Referring again to FIG. 13, the underside of the deck 212 includessupport member surfaces 222 for each support member 214 forming a bottomcenter depression 224. Support ribs 226 on the underside of the deck 212extend transversely to the deck ribs 215 and channels 216 for improvedsupport and stability.

At the side center support member 214, the notch portions 240 areformed, as shown in FIGS. 14 and 15. Converging angled sides 244 form anut portion and a rounded tip which may be configured from receiving acomplementary alignment member, such as a roller. The sides 244 alsoangle inward to provide better guidance and alignment. The notch portion240 stops below the planar deck portion 212 to provide greater supportarea for the deck 212. The notched portion 240 is also configured with anarrowed section 246 between an upper section notch for receiving analignment member of a stationary device and a lower section for guidinga complementary alignment device. As with the first embodiment notch 40,the notched portion 240 provides alignment of the pallet from its centerrelative to another surface, but also provides an upper deck providingsupport extending to the edge along its entire length.

It is to be understood, however, that even though numerouscharacteristics and advantages of the present invention have been setforth in the foregoing description, together with details of thestructure and function of the invention, the disclosure is illustrativeonly, and changes may be made in detail, especially in matters of shape,size and arrangement of parts within the principles of the invention tothe full extent indicated by the broad general meaning of the terms inwhich the appended claims are expressed.

What is claimed is:
 1. A pallet comprising: a rectangular support deckhaving a substantially planar upper supporting surface including aplurality of channels formed therein extending across the pallet, afirst deck edge and a second opposed deck edge; a plurality of supportmembers extending from an underside of the deck; an alignment portioncomprising a v-shaped notch formed along the first deck edge at a firstend of the channels, wherein the notch includes vertical sides extendingfrom a first wide end inward from to a second narrow end, wherein thefirst end is proximate the first deck edge and the second end is spacedinward from the first deck edge; wherein the v-shaped notch is centeredalong the first edge of the deck.
 2. A pallet according to claim 1,further comprising a second alignment portion formed along the seconddeck edge of the deck at a second end of the channels.
 3. A palletaccording to claim 1, wherein the deck includes a central portionprojecting substantially to the planar upper supporting surface anddefining a top recess around the central portion extending to a depth nogreater than the channels, wherein the central portion and associatedtop recess are substantially aligned with a support member wherein eachsupport member defines a bottom recess substantially aligning with thecentral portion.
 4. A pallet according to claim 1, further comprisingsupport ribs formed in the underside of the support deck, and whereinthe support ribs extend substantially perpendicular to the channels. 5.A pallet according to claims 1, wherein the underside of the deckincludes cavities formed therein for receiving support members, wherebypairs of the pallets may be stacked with undersides opposing one anotherand the support members seating in corresponding cavities of theadjacent pallet.
 6. A pallet according to claim 1, wherein each of saidsupport members includes a central portion projecting substantially tothe planar upper supporting surface and defining a top recess around thecentral portion extending to a depth no greater than the channels,wherein each support member defines a bottom recess aligning with thecentral portion.
 7. A pallet according to claim 1, wherein the v-shapednotch is formed in at least one of the support members proximate thecenterline of the pallet, wherein the support deck extends above andover the notch to define the first edge as a continuous straight edge.8. A pallet according to claim 1, wherein the deck includes a pluralityof banding holes formed there through.
 9. A pallet according to claim 1,further comprising a second v-shaped alignment notch formed at a centerof the second deck edge opposite the first deck edge.
 10. A palletaccording to claim 1, wherein the alignment portion includes first andsecond sides extending inward toward one another from the first edge atan oblique angle to the first edge.
 11. A pallet according to claim 10,further comprising a second alignment portion formed along the seconddeck edge at a second end of the channels, wherein the second alignmentportion includes first and second sides extending inward toward oneanother from the second deck edge at an oblique angle to the second deckedge.
 12. A pallet according to claim 1, wherein sides of the notchextend inward from the first deck edge.
 13. A pallet comprising: arectangular support deck having a substantially planar upper supportingsurface including a plurality of channels formed therein extendingacross the pallet, a first deck edge and a second opposed deck edge; aplurality of support members extending from an underside of the deck; analignment portion comprising a v-shaped notch formed along the firstdeck edge at a first end of the channels, wherein the notch includesvertical sides extending from a first wide end inward to a second narrowend, wherein the first end is proximate the first deck edge and thesecond end is spaced inward from the first deck edge.
 14. A palletaccording to claim 13, wherein the first end of the notch is aligned atan oblique angle to the first edge.